For Product Managers and Design Engineers, the “sticker shock” of manufacturing tooling is a familiar pain.

For Product Managers and Design Engineers, the “sticker shock” of manufacturing tooling is a familiar pain.

You design a sleek, functional housing for a new medical ventilator or an industrial control kiosk. Then, you get the quote for the Injection Molding dies: $50,000 to $100,000+. For a product that might only sell 500 to 2,000 units a year, the math simply doesn’t work. The amortization cost per part destroys your profit margin.

Many assume the only alternative is sheet metal (which limits design) or 3D printing (which is too slow for production). But there is a third way.

Vacuum Forming (Thermoforming) is the definitive manufacturing solution for low-to-mid volume production. Here is why it beats Injection Molding for your specialized enclosures.

1. The “Tooling Cost” Reality Check

Injection molding requires complex, double-sided steel molds capable of withstanding massive pressure.

Vacuum forming, however, uses single-sided molds—often made from aluminum or composite materials—because the process relies on vacuum pressure rather than mechanical force.

• The Difference: Vacuum forming tooling typically costs 50% to 80% less than injection molding tooling.
• The Win: This lower barrier to entry allows startups and specialized manufacturers to launch products without a massive upfront capital expenditure (CapEx).

2. The “Sweet Spot” for Production Volumes

Injection molding is king when you need 100,000 parts. But for Medical Devices (like MRI machines, centrifuges, or carts) and Industrial Kiosks, annual volumes rarely hit those numbers.

If you are producing between 100 and 3,000 units per year, Vacuum Forming is your financial “Sweet Spot.” You get the repeatability and professional look of plastic, but your cost-per-part remains competitive because you aren’t paying off a six-figure mold.

3. Agility: Iteration without Penalty

In the medical and industrial sectors, designs change. A new sensor requires a new port; a screen upgrade changes the bezel size.

Modifying a hardened steel injection mold is famously difficult, expensive, and time-consuming. Modifying an aluminum vacuum forming tool is comparatively fast and affordable. This flexibility allows you to upgrade your product line annually without being “locked in” to an obsolete design by expensive tooling.

4. Aesthetics: Debunking the “Cheap” Myth

A common misconception is that vacuum-formed parts look “simple.” That might have been true 20 years ago, but not today.

At Mega Fibre, we produce enclosures that are indistinguishable from injection-molded counterparts.

• Complex Details: With Pressure Forming (an advanced variant of thermoforming), we can achieve sharp crisp lines, textured surfaces, and molded-in logos.
• EMI/RFI Shielding: For medical and electronic applications, we apply conductive coatings inside the enclosure to protect sensitive electronics from interference.
• Premium Finishing: Our in-house paint shop ensures your enclosures meet the strict hygiene standards of a hospital or the rugged durability requirements of a factory floor.

Conclusion: Don’t Overpay for Tooling

Your budget should go toward innovation, not steel.

If you are launching a new device and the volume doesn’t justify injection molding, Vacuum Forming is the answer. It offers the design freedom of plastic with the economic agility your business model demands.

Mega Fibre specializes in helping OEMs navigate this decision. We provide the enclosures that house the technology saving lives and powering industries.

[Request a Quote Comparison] today. Let us show you how much you can save on tooling for your next project.